Standard Specification for Repairing Concrete

with Epoxy Mortars (ACI 503.4-92, Reapproved 1997, 2003)

Reported by ACI Committee 503
R.W. Gaul
Chairman
Russell H. Brink
George Horeczko
Harold C. Klassen
Joseph A. McElroy

George Selden
Secretary
Leonard J. Mitchell
Myles A. Murray
Leonard Pepper

G.M. Scales
Raymond J. Schulz
George W. Whitesides

Committee voting on the 1992 revisions:

Myles A. Murray
Secretary

Raymond J. Schutz
Chairman
Milton D. Anderson
Roger W. Black
John P. Cook
Floyd E. Dimmick
Wolfgang D. Eisenhut
Jack J. Fontana
Robert W. Gaul
Paul R. Hollenbach

David P. Hu
T. Michael Jackson
Troy D. Madeley
Albert Mayer
Joseph A. McElroy
Paul F. McHale
Peter Mendis

This specification describes the work of repairing defects in hardened

portland cement concrete with a sand-filled mortar using an adhesive
binder such as defined in ASTM C 881. It includes controls for adhesive
labeling storage, handling, mixing and application, surface evaluation and
preparation as well as inspection and quality control.
Keywords: bond (concrete to concrete); concrete construction; epoxy
resins, hardened concrete; mortars (material); quality control; repairs;
resurfacing; specifications; standards.

FOREWORD

Richard Montani
Joseph M. Plecnik
Hamid Saadatmanesh
W. Glenn Smoak
Joe Solomon
Michael M. Sprinkel
Douglas G. Walters

fication(s) for any building project, together with supplementary requirements for the specific project.
This specification is written in the section and three-part
format of the Construction Specifications Institute, but with
the numbering system modified to ACI requirements. The
language is generally imperative and terse.
A specification guide and checklist are included as a
preface to, but not forming a part of Standard Specification ACI 503.4. The purpose of this guide and checklist
is to assist the Architect/Engineers' d e s i g n e r ( s ) a n d
specifier(s) to properly choose and specify the necessary
supplementary requirements for the project specification(s).

This foreword is included for explanatory purposes only; it

does not form a part of Standard Specification ACI 503.4.
Standard Specification 503.2 is a reference standard
which the Architect/Engineer may cite in the project speciA C I Committee Reports, Guides, Standard Practices, and
Commentaries are intended for guidance in designing, planning, executing, or inspecting construction and in preparing
specifications. References to these documents shall not be
made in the Project Documents. If items found in these
documents are desired to be a part of the Project Documents, they should be phrased in mandatory language and
incorporated into the Project Documents.

* Adopted as a standard of the American Concrete Institute effective June 1979.

in accordance with the Institutes standardization procedure. It was revised
according to the expedited procedure effective October 1986 and March 1992,.
Copyright 8 1978 and 1986 American Concrete Institute.
All rights reserved including rights of reproduction and use in any form or by
any means. including the making of copies by any photo process, or by any electronic or mechanical device. printed or written or oral, or recording for sound or
visual reproduction or for use in anv knowledge or retrieval system or device,
unless permission in writing is obtained from the copyright proprietors.

503.4-l

503.4-2

CONTENTS

SPECIFICATION GUIDE

Specification guide, pg. 503.4-2

Specification checklist, pg. 503.4-2
Section l-General requirements, pg. 503.4-4
1.1-Scope
1.2-Notation
1.3--Specification wording
1.4-Reference standards
Section 2-Materials and application, pg. 503.4-4

Part 2.1-General, pg. 503.4-4

2.1.1-Description
2.1.2-Submittals
2.1.3-Quality assurance
2.1.4-Product delivery, storage, and handling
2.1.5-Project conditions

SGl-Standard Specification ACI 503.4 is intended to

be used essentially in its entirety, by citation in the
project specification, to cover all usual requirements for
repairing concrete with epoxy mortars. Individual sections, parts, and articles should not be copied into project
specifications since taking them out of context may
change their meanings.
SG2-However, adjustments to the needs of a particular project shall be made by the Architect/Engineers
designers and specifiers by reviewing each of the items
indicated in this specification guide and checklist and
then including their decisions on each as mandatory
requirements in the project specification.
SG3-These mandatory requirements shall designate
specific qualities, procedures, materials, and performance
criteria for which alternatives are permitted or for which
provision is not made in Standard Specification ACI
503.4. Or exceptions shall be taken in Standard Specification ACI 503.4 if required.
SG4-A statement such as the following will serve to
make Standard Specification ACI 503.4 an official part of
the contract requirements:
Repairing concrete with epoxy mortars shall conform
to all requirements of Standard Specification for
Repairing Concrete with Epoxy Mortars (ACI 503.4),
published by the American Concrete Institute, Detroit, Mich., except as modified by the requirements
of this project specification.

Part 2.2-Products, pg. 503.4-4

2.2.1-Epoxy mortar
Part 2.3-Execution, pg. 503.4-4
2.3.1-Preparation of concrete surfaces
2.3.2-Inspection of concrete surfaces prior to mortar
application
2.3.3-Mortar mixes
2.3.4-Mortar application
2.3.5-Cleanup
2.3.6-Safety

SG5-The specification checklist that follows is addressed to each item of ACI 503.4 that requires the
designer/specifier to make a choice where alternates are
indicated, or to add provisions where they are not indicated in ACI 503.4, or to take exceptions to ACI 503.4.
The checklist consists of one column identifying sections,
parts, and articles of ACI 503.4, and a second column of
notes to the designer/specifier to indicate the action
required of them.

SPECIFICATION CHECKLIST
Section/Part/Article of ACI 503.4

Notes to the Designer/Specifier

Section l-General requirements

1.1 Scope

Indicate specific scope.

1.4 Reference standards

Review applicability of cited references and take exceptions if required.

Section 2-Materials and application

2.1.2 Submittals

To whom sent?

EPOXY RESINS

503.4-3

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of ACI 503.4

Notes to the Designer/Specifier

2.1.3.2 Application control

Mixing and application procedures submitted must be

in accordance with product manufacturers instructions.

2.1.4.2 Storage of materials

Storing epoxy compounds at other than specified temperature range may result in degradation of the product. If such storage takes place, manufacturer should
be contacted before product is used.

2.1.5.1 Environmental requirements

Performance of epoxy systems may be affected by temperature, humidity, and surface water. Strict adherence
to the manufacturers recommendations should be
maintained. Where other unusual conditions are encountered, the material manufacturer should be consulted before application.

2.2.1 Epoxy mortar

Epoxy mortars consist of a two component epoxy system plus aggregate which may or may not be incorporated in one or both components. Since the amount and
type of aggregate is important to the performance of
the mortar, the supplier and contractor must be in full
agreement on selection and use. If the aggregate is
furnished with proper instructions by the supplier the
problem is minimized.
The amount and type of aggregate selected can result in a mortar mix that will not adequately wet the
concrete substrate and thus can result in a poor bond.
The manufacturers recommendations should be closely followed regarding the need for and application of a
primer for the mortar mix selected.

2.3.1 Preparation of surfaces

Specify limitations, if any, on use of mechanical

abrasion, and on disposal of waste products.

2.3.2 Inspection of surfaces

Specify if architect/engineer will also inspect, and if

hold points are required.

2.3.2.2 Pullout strength tests

The test method specifies the bonding of a steel pipe

cap to the concrete surface with an epoxy adhesive. If
the test results not in failure of the concrete but in
cohesion of the epoxy resin adhesive or any failure in
adhesion, the test shall be repeated. Repeated failures
in adhesion, or cohesion in the adhesive, indicate improper cleaning of the concrete, incorrect adhesive, or
faulty adhesive application techniques.

2.3.2.4 Surface condition of concrete

Surface condition of the concrete must be in accordance with the suppliers recommendation. Some
mortars require a dry surface and a test method should
be available to the applicator.
Some epoxy adhesives may be capable of wetting
the concrete surface at temperatures below 40 F. The
specification should allow such use only if test data is
available which conclusively demonstrates adequate
bond at the actual concrete temperature expected.

503.4-4

ACI STANDARD

SPECIFICATION CHECKLIST (cont.)

Section/Part/Article of ACI 503.4

2.3.4.1 Mortar application

SECTION l-GENERAL REQUIREMENTS

l.l-Scope
1.1.1 This standard specification covers repairing of

defects in hardened portland cement concrete with sandfiied epoxy mortar.

1.1.2 The provisions of this standard specification shall
govern unless otherwise specified in the contract documents. In case of conflicting requirements, the contract
documents shall govern.
1.2-Notation

1.2.1 ACI:

American Concrete Institute

P.O. Box 19150
Detroit, MI 48219

1.2.2 ASTM: American Society for Testing and

Materials
1916 Race Street
Philadelphia, PA 19103
1.3-Specification wording
1.3.1 The language of this standard specification is
generally imperative and terse, and may include incomplete sentences. Omissions of phrases and of words such
as the contractor shall, in accordance with, shall be,
as indicated, a, an, the, all, etc., are intentional.
Omitted phrases and words shall be supplied by inference.
1.4-Reference standards
1.4.1 The standards referred to in this Standard Specification ACI 503.4 are listed in Article 1.5.2 of this
section, with their complete designation and title including the year of adoption or revision and are declared
to be a part of this Standard Specification ACI 503.4 the
same as if fully set forth herein, unless otherwise indicated in the contract documents.
1.4.2 ASTM standard
C 881-87 Standard Specification for Epoxy-Resin-Base
Bonding Systems for Concrete
SECTION 2-MATERIALS AND APPLICATION

Part 2.1-General

Notes to the Designer/Specifier

Too thin an application of epoxy mortar can result in a

surface without adequate integrity for intended use.
Too thick an application can result in delamination
caused by temperature changes. See Use of Epoxy
Compounds with Concrete reported by Committee 503
for a more complete explanation.

2.1.1 Description - This section covers the requirements for surface preparation of hardened concrete and
for materials and application of the epoxy mortar.
2.1.2 Submittals
2.1.2.1 Contractor shall submit manufacturers
certification verifying conformance to material specifications specified in Part 2.2.
2.1.3 Quality assurance
2.1.3.1 Labeling-Clearly mark all containers with
the following information:
a)
b)
c)
d)

Name of manufacturer
Manufacturers product identification
Manufacturers instructions for mixing
Warning for handling and toxicity

2.1.3.2 Application control-Submit mixing and

application procedures for approval prior to use.
2.1.4 Product delivery, storage, and handling
2.1.4.1 Delivery of materials-Deliver all materials
in sealed containers with labels legible and intact.
2.1.4.2 Storage of materials-Store all materials at
temperatures between 40-100 F (5-38 C) unless otherwise
recommended by manufacturer.
2.1.4.3 Handling of materials--Handle all materials
in a safe manner and in a way to avoid breaking container seals.
2.1.5 Project conditions
2.1.5.1 Environmental requirements-Contractor
shall comply with manufacturers recommendations as to
environmental conditions under which the epoxy compound may be applied.
Part 2.2-Products
2.2.1 Epoxy mortar-ASTM C 881 Type III. Curing
temperature requirements (Class) and viscosity (Grade),
as well as special requirements regarding filling of either
the components or the final system, shall be determined
by supplier and contractor after project conditions have
been established.
Part 2.3-Execution
2.3.1 Preparation of concrete surfaces
2.3.1.1 Concrete surfaces to which epoxies are to be
applied shall be newly exposed parent concrete free of
loose and unsound materials. Prepare surfaces by mech-

EPOXY RESINS

anical abrasion.
2.3.1.3 Mechanical abrasion-Use sandblasting,
scarifying, waterblasting, or other approved means.
2.3.2 Inspection of concrete surfaces prior to mortar application
2.3.2.1 Inspect all concrete surfaces prior to
application of mortar to insure that requirements of this
Article 2.3.2 are met.
2.3.2.2 Surfaces shall be sound concrete which
exhibits a minimum 100 psi pullout strength when tested
in accordance with Appendix A of Use of Epoxy Compounds with Concrete, reported by ACI Committee 503.
2.3.2.3 Surfaces shall be free of any deleterious
materials such as laitance, curing compounds, dust, dirt,
and oil. Materials resulting from surface preparation specified in Article 2.3.1 shall be removed.
2.3.2.4 All concrete surfaces shall be dry as defined
in Article 2.3.2.5 below unless a water-insensitive coating
is used. Surface temperature shall be at least 40 F to permit wetting of concrete surface by epoxy coating.
2.3.2.5 Evaluate moisture content for concrete by
determining if moisture will collect at bond lines between
old concrete and epoxy coating before epoxy has cured.
This may be accomplished by taping a 4 x 4 ft polyethylene sheet to concrete surface. If moisture collects on
underside of polyethylene sheet before epoxy would cure,
then allow concrete to dry sufficiently to prevent the
possibility of moisture between old concrete and new
epoxy.
2.3.3 Mortar mixes
2.3.3.1 Mix epoxy components in a clean container
free of harmful residue or foreign particles.
2.3.3.2 Condition epoxy compound components to

503.4-5

be at a temperature between 60-100 F (16-38 C), unless

otherwise recommended by manufacturer.
2.3.3.3 Thoroughly blend epoxy components with a
mechanical mixer to a uniform and homogeneous mixture. Mix small batches (up to 1 qt) by use of spatulas,
palette knives, or similar devices.
2.3.4 Mortar application
2.3.4.1 Apply epoxy mortar to concrete surface by
trowel or screed. Thickness shall be within the limits recommended by the manufacturer.
2.3.4.2 Work mortar into place and consolidate thoroughly so that all contact surfaces are wet by the mortar
and entrained air is reduced to the level recommended
by manufacturer.
2.3.4.3 Finish surface of mortar to texture, color,
and smoothness required for the specific application.
2.3.4.4 Upon completion of finishing operations,
allow mortar to cure in accordance with manufacturers
recommendations.
2.3.5 Cleanup
2.3.5.1 Protect concrete surfaces, beyond limits of
surface receiving mortar, against spillage.
2.3.5.2 Immediately remove any epoxy compound
applied or spilled beyond desired areas. Perform cleanup
with material designated by epoxy mortar manufacturer.
Avoid contamination of work area.
2.3.6 Safely-Epoxy materials may be skin irritants or
sensitizers to many people. Accordingly, advise applicators to avoid contact with eyes and skin, inhalation of
vapors, and ingestion. Make protective and safety equipment available on site. Heed all label warnings by manufacturer. Make application in accordance with applicable
safety laws.